Polaris SPORTSMAN 400 2003 Service Manual page 159

CLUTCH
Rollers
ROLLER PIN DISASSEMBLY
New roller retaining bolts have a dry locking agent
applied to the threads. Before attempting to remove
the roller pins, heat the threaded area lightly with a
propane torch. Wear heat resistant gloves during
this procedure. Use a high quality hexagonal
wrench in good condition to avoid screw damage. A
small amount of valve grinding compound can be
applied to the tip of the hex wrench to ensure a tight
fit. Always use new bolts if they are removed for
inspection. Apply Loctitet 680 retaining compound
sparingly to the tapered head portion of the roller
retaining screws. Do not allow locking agent to
contact the inside of the rollers. Do not lubricate the
roller or roller pin.
Heat Area
Roller
Lightly
6.28
Apply Loctitet
680 To Tapered
Portion Of Screw
Dry Locking
Agent Applied
To New Screws
DRIVEN CLUTCH DISASSEMBLY/ INSPECTION
CONT'D
7. Inspect moveable sheave bushing for wear.
Inspect BOTH sheaves for signs of wear,
grooving or cracking. Clean surfaces with a 3Mt
pad if needed
Moveable Sheave Bushing Inspection:
Replace the bushing if more brass than
Teflont is visible on the surface of the
bushing.
8. Check for movement of the shaft in the one-way
clutch. If the shaft can be moved laterally, or if the
one-way clutch does not function properly as
described in Step 1 and 2 on Page 6.26, replace
driven clutch assembly.